Coextruded multilayer plastic container utilizing post consumer plastic

Abstract: A coextruded multilayer plastic container utilizing post consumer plastic resin comprising an appearance enhancing thin outer layer of ethylene polymers, which enhances the appearance of the container, an intermediate layer comprising a fusion blend of post consumer resin with or without colorant and a third layer comprising a fusion blend of post consumer resin which may have mixed colors. In a modified and preferred form, a fourth inner layer of virgin ethylene polymer is provided.

Description: This invention relates to a multilayer coextruded plastic container and to a method of forming same. In the use of plastic materials for containers such as bottles, it has been found desirable to attempt to recycle and reuse the plastic which is commonly known as post consumer plastic (PCP) or post consumer resin (PCR). In attempts to make containers from such materials, it has been found that the properties have been adversely affected. Specifically when containers are made from recycled post consumer high density polyethylene homopolymers (HDPE) container scrap, it has been found that the containers have diminished physical properties. Such containers made of high density polyethylene homopolymers also have been used for packaging of certain types of liquid detergent products. The use of such containers to package liquid detergent products has been somewhat restricted, however, by reason of the fact that many types of liquid detergent products accelerate the tendency of the container to exhibit stress cracking. Stress cracking is evidenced by the appearance of hazy cracks in the container which are aesthetically unpleasing to the ultimate consumer. In extreme cases, stress cracking can lead to leakage of the contents from the container. Stress cracking can occur when the containers are for liquid products including liquid detergents and liquid hypochlorite bleaches. It has been suggested that such post consumer resin be utilized because large quantities of high density polyethylene post consumer resin are available due to the extensive use of high density polyethylene in large containers for milk and water. Post consumer resin from such containers contains contaminants of paper and other plastic resins, for example, from closures such that it has been generally thought that it can not be used to make satisfactory plastic containers. A container with the features of the preamble to claim 1 is known from Plastic Engineering, Vol. 49, No. 9, March 1992, Brookfield, CT, USA, that discloses coextruded bottles having a three-layer sandwich of a scrap core layer between exterior and interior virgin-only layers. Dark crap can be masked by an interposed, additional pigmented white virgin layer between the exterior surface layer and the scrap-containing layer. In EP-A-0 561 187 which is prior art under Art. 54(3) EPC, there is disclosed a plastic container made from a fusion blend of a post consumer plastic and ethylene polymers and comprising post consumer resin of homopolymer high density polyethylene resin and a small amount of linear low density polyethylene resin. In another form, the container is made from a blend of post consumer homopolymer high density polyethylene resin, virgin high density polyethylene resin with a small amount of linear low density polyethylene resin. The physical properties of the container including stress cracks resistance are maintained as contrasted to the loss of such physical properties that have been heretofore resulted from the use of post consumer resins. Large quantities of plastic resin are used to make containers which have an attractive appearance provided by additives which function to provide gloss or attractive colors. Such additives are quite expensive. As far as the present inventors are aware, it has not heretofore been thought to have been possible to utilize post consumer resin to make plastic containers wherein the container has additives to enhance gloss, or color, which requires expensive colorants because of the gray colors that are inherent in the post consumer resin. Among the objectives of the present invention are to provide a plastic container which has an outer appearance layer; which not only utilizes post consumer plastic but also permits the use of post consumer resin having various colors therein; wherein plastic container is constructed and arranged such that the post consumer resin having multiple colors is obscured and results in a container that provides an attractive appearance; wherein a relatively dark, thick, post consumer resin layer comprises the major portion of the container is not visible; wherein the container can have a significant attractive appearance color; and wherein the container results in significant resin savings. The invention is defined in claims 1 and 11. In accordance with the invention, a coextruded multi-layer plastic container utilizing post consumer plastic resin comprising an appearance enhancing thin outer layer comprising a, fusion blend of ethylene polymers and a colorant which enhances the appearance of the container, an intermediate layer comprising a fusion blend of post consumer recycled resin including colorants and a third layer comprising post consumer resin which may have mixed colors. In a modified and preferred form, a fourth inner layer of virgin ethylene polymer is provided over the third inner layer. FIG. 1 shows a plastic container embodying the invention. FIG. 2 is a fragmentary sectional view on a greatly enlarged scale taken along the line 2-2 in FIG. 1 diagrammatically showing the cross section of the container. FIG. 3 is a fragmentary sectional view on a greatly enlarged scale diagrammatically showing the cross section of a modified form of container. FIG. 4 is a fragemetnary sectional view on a greatly enlarged scale diagrammatically showing the cross section of another modified form of container. Referring to FIG. 1, a multilayer hollow plastic container 10 embodying the invention is preferably made by coextruding a multilayer parison and then blow molding the container having a body portion 11, a base portion 12, a shoulder portion 13 and a neck portion 14 with a finish 15. Referring to FIG. 2, in a preferred form, the container 10 comprises four layers; an outer thin appearance enhancing plastic layer A comprising a fusion blend of ethylene homopolymer polymers and an additive for enhancing the appearance; an adjacent thin plastic layer B which functions to mask the color of a third thicker plastic layer C one which comprises a fusion blend of post consumer resin which may have mixed colors. A fourth thin inner plastic layer D of virgin ethylene homopolymer is provided on the interior of the container which protects the contents of the container where needed. In the form shown in FIG. 3, the inner layer D is omitted. The plastic resin of the outer layer A may comprise a fusion blend of ethylene copolymers such as linear low density polyethylene, low density polyethylene, high density polyethylene, or mixtures thereof and an appearance enhancing additive. Typical additives for enhancing comprise pigments providing bright attractive colors; flakes for providing pearlescent effects, such as aluminum or calcium carbonate flakes; and fluorescent dyes or pigments which absorb light at one wave length and emit light of greater wave length as is well known; and polymers of selected molecular weights which provide a high gloss appearance. The thin plastic layer B may comprise a fusion blend of ethylene polymer, preferably virgin high density polyethylene or post consumer resin and an appearance enhancing additive which will mask the post consumer resin in the thick layer C. Post consumer resin contains primarily the plastic from high density polyethylene homopolymer containers used for packaging milk and colored plastic containers and possible polypropylene resin from syrup bottles, multi-layer ketchup bottles and caps. Such post consumer resin may have the properties set forth in the following Table I. PROPERTY SPECIFIED VALUE Material Density .960 ± .02 natural Melt Flow - Melt Index 0.5 ± 0.3 dgm Fines <0.01% Moisture <0.05% Contamination Paper <0.01% Plastic-Dens. >1.0 gm/cc <0.1% The thin inner layer D, when used, comprises ethylene copolymers such as virgin high density polyethylene or linear low density polyethylene. In each form the major portion of the thickness of the wall of the container is in thick layer C of post consumer resin. The linear low-density ethylene polymer(s) of the invention have a density in a range of about 0.91 to about 0.93 g/ml, preferably in a range of about 0.92 to about 0.93 g/ml, and especially about 0.925 g/ml. The linear, low-density ethylene polymers will have a melt index of less than about 2.0 and preferably less than about 1.0 g/10 min. It is desirable for the melt index to be close to the melt index of the linear high-density ethylene polymer included in the blend. These polymers are ethylene copolymers having polymerized about 2-6 and preferably about 4-6 mol % of an alpha-monoolefin containing 3 to 12 carbon atoms with the balance of the monomer polymerized therein being ethylene. The linear low-density ethylene polymers employed in the present invention have long linear chains with controlled numbers of relatively short chain branches attached to the linear chain along its entire length. The low density polyethylene homopolymer comprises utilized in the outer layer has a melt index of at least 2 and preferably less than 1; and a density of not greater than 0.93 g/ml. The low density polyethylene comprises the outside high gloss layer. The low density polyethylene has melt index of at least 2 and preferably less than 1 and will have a density mzx of 0.93 g/ml. The virgin high density copolymer resin contains linear high-density ethylene polymer. The linear high-density ethylene copolymer included in the blends will have a density of at least about 0.94 g/ml, a melt index of less than about 0.5 g/10 min and will have polymerized therein at least about 98 mol % ethylene with any comonomer polymerized therein being an alpha-monoolefin containing about 3 to 12 carbon atoms. Such linear high-density ethylene polymers are known and reported in the art and are commercially available from numerous commercial producers. Such linear high-density ethylene polymers are prepared by polymerizing ethylene, optionally in the presence of an alpha-monoolefin comonomer containing 4 to 12 carbon atoms in the presence of certain metallic catalysts such as chromium catalysts, e.g. CrO 3 supported on silica-alumina supports, and the Ziegler-Natta catalysts, e.g. TiCl 3 employed in conjunction with certain aluminum alkyl cocatalysts. The requisite density and melt index desired in the polymer are obtained by proper control of polymerization conditions including temperature, pressure, comonomer concentration, and the concentration of telegenating agents such as hydrogen. The preferred linear high-density ethylene polymers will have a density of at least about 0.94 g/ml. The especially preferred polymers will have a density of at least about 0.95 g/ml. Stress crack resistance is conventionally conducted with test methods as established by Technical Bulletin PBI 11-1978 of the Plastic Bottle Institute, Rev.1-1991 or ASTM D2561-70 (Reapproved 1989). Typical examples of thicknesses of side walls of a container embodying the invention are: Four layer thin layer A 0,05-0,5 mm thin layer B 0,05-0,25 mm thick layer C 0,127-0,762 mm thin layer D 0,025-0,254 mm Three layer thin layer A 0,05-0,5 mm thin layer B 0,05-0,25 mm thick layer C 0,127-0,762 mm Three layer thin layer A 0,076-0,5 mm thick layer B 0,2-0,76 mm thin layer C 0,025-0,254 mm Examples of specific compositions of the layers in containers are as follows: Example I Thin layer A - glossy high density polyethylene and pearlescent additive Thin layer B - post consumer resin (milk) and T i O 2 colorant Thick layer C post consumer resin (mixed color) and regrind Thin layer D - virgin high density polyethylene and colorant Example II Thin layer A - glossy high density polyethylene Thin layer B - post consumer resin (milk) and T i O 2 colorant Thick layer C post consumer resin (mixed color) and regrind Thin layer D - virgin high density polyethylene and colorant Example III Thin layer A - glossy low density polyethylene Thin layer B - post consumer resin (milk) and T 1 0 2 colorant Thick layer C post consumer resin (mixed color) and regrind Thin layer D - virgin high density polyethylene Metal fragments None Other (glass, stone) None Example IV Thin layer A - virgin high density polyethylene, glossy high density polyethylene and linear low density polyethylene Thin layer B - post consumer resin (milk) and T 1 0 2 colorant Thick layer C - adhesive layer - Post consumer resin and regrind Thin layer D - Nylon In the form shown in FIG. 4, the inner player layer D' is made of a solvent resistant material, such as nylon, to provide a construction whereby the container can be used for solvent products such as petroleum distillates. In this form, the third layer C' comprises post consumer recycled polyethylene resin, process trim and offware scrap. An adhesive layer (not shown) is provided between the layer B and layer C' and also between layer C' and layer D' for layer adhesion. This adhesive layer comprises a nylon/polyethylene adhesive. As shown in the drawings, the layer C, C' comprises the major portion of the thickness. It can thus be seen that there has been provided a coextruded multi-layer plastic container utilizing post consumer plastic resin comprising an appearance enhancing thin outer layer comprising a fusion blend of ethylene polymers and a colorant which enhances the appearance of the container, an intermediate layer comprising a fusion blend of post consumer recycled resin including colorants and a third layer comprising post consumer resin which may have mixed colors. In a modified and preferred form, a fourth inner layer of virgin ethylene polymer is provided over the third inner layer. It can thus be seen that there has been provided a plastic container which has an outer appearance layer; which not only utilizes post consumer plastic but also permits the use of post consumer resin having various colors therein; wherein plastic container is constructed and arranged such that the post consumer resin having multiple colors is obscured and results in a container that provides an attractive appearance; wherein a relatively dark, thick, post consumer resin layer comprises the major portion of the container is not visible; wherein the container can have a significant attractive appearance color; and wherein the container results in significant resin savings.

Claims: A multilayer coextruded plastic container having walls comprising a thin outer plastic layer (A, A') including virgin ethylene polymer, a relatively thick inner layer (C, C') including post consumer resin which layer contributes the major portion of the container wall; and a thin intermediate opaque plastic layer (B, B') masking said post consumer resin of said relatively thick inner layer (C, C'), characterized in that said thin outer plastic layer (A, A') is a fusion blend of said virgin ethylene polymer and an appearance enhancing additive and said thin intermediate opaque plastic layer (B, B') comprises a fusion blend of post consumer resin including colorants. The container of claim 1 wherein said layers (A, B, C) are bonded to one another by heat during coextrusion. The container set forth in claim 2 including a fourth layer (D) of virgin polymer resin over the inner layer (C, C') and forming the inner surface of the container. The container set forth in claim 1 or 2 including a further inner layer (D') made of solvent resistant plastic resin which forms the inner surface of the container. The container set forth in claim 4 wherein said solvent resistant plastic resin comprises nylon including an adhesive layer between the intermediate opaque layer (B') and the inner layer (C') of post consumer resin and an adhesive layer between the inner layer (C') of post consumer resin and said further inner layer (D') of solvent resistant plastic, each said adhesive layer comprising a nylon/polyethylene adhesive. The container set forth in any one of claims 1 to 4 wherein the appearance enhancing additive is selected from the group comprising pigments, pearlescent additives, fluorescent additives and glossy molecular weight resins. The container of any of claims 1 to 6 wherein said appearance enhancing additive in said thin outer plastic layer (A, A') contains a glossy high density polyethylene. The container of any of claims 1 to 7 wherein said intermediate layer (B) comprises post consumer resin from milk containers, and a colouring pigment. The container of any of claims 1 to 8 wherein said relatively thick inner layer (C) also includes regrind besides of said post consumer resin. The container set forth in any of claims 7 to 9 including a fourth layer (D) over said inner layer (C) comprising a fusion blend of virgin high density polyethylene and colorant, said further inner layer (D) forming the inner surface of the container. A method of forming a multilayer coextruded plastic container comprising the steps of providing a multilayer parison which has a thin outer layer (A, A') including virgin ethylene polymer, a relative thin intermediate opaque layer (B, B') and a relative thick inner layer (C, C') of post consumer resin, blow molding the parison to form a container, wherein the inner layer (C, C') of post consumer resin comprises the major portion of the container and said opaque layer (B, B') maskes the post consumer resin, characterized by providing a thin outer layer (A, A') which is a fusion blend of virgin ethylene polymer and an appearance enhancing additive, and providing a thin intermediate opaque plastic layer (B, B') which comprises a fusion blend of post consumer resin including colorants. The method set forth in claim 11 including coextruding a fourth layer (D) of virgin polymer resin over the inner layer (C, C') so as to prepare forming of the inner surface of the container. The method set forth in claim 11 including a further inner layer (D') made of solvent resistant plastic resin which forms the inner surface of the container. The method set forth in claim 13 wherein said solvent resistant plastic resin comprises nylon including an adhesive layer between the intermediate opaque layer (B') and the inner layer (C') of post consumer resin and an adhesive layer between the inner layer (C') of post consumer resin and said further inner layer (D') of solvent resistant plastic, each said adhesive layer comprising a nylon/polyethylene adhesive. The method set forth in any one of claims 11 to 13 wherein the appearance enhancing additive is selected from the group comprising pigments, pearlescent additives, fluorescent additives and glossy molecular weight resins. The method set forth in claim 11 wherein said outer layer (A, A') comprises a fusion blend glossy high density polyethylene as said appearance enhancing additive; said intermediate layer (B, B') comprises post consumer resin from milk containers and a coloring pigment and said inner layer (C, C') comprises post consumer resin with mixed colors and regrind. The method set forth in claim 16 including coextruding a fourth layer (D1) over said inner layer (C, C') comprising a fusion blend of virgin high density polyethylene and colorant so as to prepare forming of the inner surface of the container.

Inventors: MOORE DUANE H, RITTER RICHARD W M JR, MOORE, DUANE H., RITTER JR., RICHARD W.M.
Applicants: OWENS ILLINOIS PLASTIC PROD, OWENS-ILLINOIS PLASTIC PRODUCTS INC.
Application year: 1994
Main classification: B29C49
IPC codes: B32B27, B29K23, B29K105, B29K77, B29C49, B29L9, B32B1, B29L22